Chrysler PT Cruiser. Manual — part 781
OUTPUT SHAFT
DESCRIPTION
The output shaft assembly (Fig. 200) is part of the
transaxle geartrain, meshes with and is driven by
the input shaft, drives the differential via an inte-
grated pinion gear, and consists of the following com-
ponents:
• Output Mainshaft
• 1st Speed Gear
• 2nd Speed Gear
• 3rd Gear (Fixed)
• 4th Gear (Fixed)
• 5th Gear (Fixed)
• 1/2 Synchronizer
The output shaft is supported by a caged cylindri-
cal roller bearing at the front of the transaxle, and a
sealed ball bearing at the rear of the transaxle.
Fig. 200 Output Shaft Section View
1 - FIFTH GEAR
2 - FOURTH GEAR
3 - THIRD GEAR
4 - SECOND GEAR
5 - 1/2 SYNCHRONIZER
6 - FIRST GEAR
7 - ROLLER BEARING (2)
8 - NEEDLE BEARING
9 - BUSHING
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G288 MANUAL TRANSAXLE
PT
DISASSEMBLY
(1) Install output shaft to fixture 8925-3. Use split
plate 8925-2 on diesel models, and 8925-4 on turbo
models as shown in (Fig. 201).
(2) Remove 4th and 5th gears simultaneously.
Install protective sleeve 8918 to output shaft and
press 4th and 5th gears off of shaft (Fig. 201).
(3) Install output shaft to fixture 8925-3 using
split plate 8925-1 as shown in (Fig. 202).
(4) Remove 3rd gear. Install protective sleeve 8918
to output shaft and press 3rd gear off of shaft (Fig.
202).
(5) Remove second gear from output shaft.
(6) Remove second gear needle bearing.
(7) Install output shaft to fixture 8925-3 using
split plate 8925-2 (inverted) (Fig. 203).
(8) Install protective sleeve 8918 to output shaft
and simultaneously press off 2nd gear bushing, 1-2
synchronizer, and 1st gear (Fig. 203).
Fig. 201 4th/5th Gear Removal
1 - TOOL 8918
2 - 5TH GEAR
3 - 4TH GEAR
4 - PLATE 8925-2 / 8925-4
5 - FIXTURE 8925-3
Fig. 202 3rd Gear Removal
1 - TOOL 8918
2 - 3RD GEAR
3 - SPLIT PLATE 8925-1
4 - FIXTURE 8925-3
Fig. 203 1st Gear, Synchro, and Bushing Removal
1 - TOOL 8918
2 - BUSHING
3 - 1-2 SYNCHRONIZER
4 - 1ST GEAR
5 - SPLIT PLATE 8925-2 (INVERTED)
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G288 MANUAL TRANSAXLE
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OUTPUT SHAFT (Continued)
(9) Remove 1st gear needle bearings (2) from shaft.
Inspect thrust washer (fixed to shaft) (Fig. 204).
Fig. 204 Output Shaft Assembly
1 - OUTPUT SHAFT ASSEMBLY
2 - 5TH GEAR
3 - 4TH GEAR
4 - 3RD GEAR
5 - 2ND GEAR NEEDLE BEARING
6 - BUSHING
7 - 2ND GEAR
8 - FRICTION RING
9 - CONE
10 - BLOCKER RING
11 - 1-2 SYNCHRONIZER
12 - 1ST GEAR NEEDLE BEARING (2)
13 - 1ST GEAR
14 - OUTPUT SHAFT
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G288 MANUAL TRANSAXLE
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OUTPUT SHAFT (Continued)
ASSEMBLY
(1) Install first gear roller bearing to shaft with
smaller diameter cage ring facing outward (Fig. 206)
(Fig. 205).
Fig. 205 Output Shaft Section View
1 - FIFTH GEAR
2 - FOURTH GEAR
3 - THIRD GEAR
4 - SECOND GEAR
5 - 1/2 SYNCHRONIZER
6 - FIRST GEAR
7 - ROLLER BEARING (2)
8 - NEEDLE BEARING
9 - BUSHING
Fig. 206 First Gear Roller Bearing
1 - ROLLER BEARING
2 - SMALLER RING UP
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G288 MANUAL TRANSAXLE
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OUTPUT SHAFT (Continued)
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